Apparatus and method for feed through construction

ABSTRACT

A barrier comprised of a collar defining the form factor of the barrier and a plurality of slidably connected and nested rods creating a continuous barrier conforming to the form factor of the collar. While the collar defines the form factor of the barrier, the slidable rods can be adjusted in their relative positions along the form factor to provide for a barrier that conforms to the contours of the application surface. The barrier may include means to attach the apparatus to the decking and caps to seal the apparatus during construction activities. The rods are interconnected one to another so that the rods can be connected into a continuous barrier. The rods are able to slide relative to each other along the interlocking structure. When the device is set into position, rods may be slid into a barrier structure that conforms to both planar and non-planar surfaces of the application surface. As such, the apparatus provides an effective barrier for further construction processes, e.g. pouring a cement floor while keeping cement from flowing into the desired channel or penetration.

FIELD OF THE INVENTION

This invention relates to a device and construction method for creatingportals in a constructed structure and in particular to creating portalsin poured concrete flooring.

BACKGROUND

A sleeve creates an opening known as a penetration or hole betweenfloors of buildings or other structures essential for various trades(i.e. electrical, plumbing, sprinkler fitting). Plumbing processes andmechanical needs are routed using penetrations to maximize efficiencyand minimize materials used. Large penetrations called shafts areutilized to connect each floor for large duct work and system pipes,however congestion in those shafts is avoided by having drain and ventpipes plumbed through penetrations. Electrical and data needs can bebrought up through the floor as well.

In buildings with floors made of metal decking and concrete, or justconcrete, passages are created utilizing, for example, a core drillingmethod or a boxing out method. The core drilling method generallyincludes a core drill rig, specialized wet core bits and water. Theconcrete is poured, creating the floor without any penetration. Once theconcrete cures, holes of various sizes are drilled using a core drillrig with a wet core bit. This method requires a water source to keep thebit cool, two people (one to keep watch below while the other cuts),clean up and a lot of time.

The boxing out method includes structures and material such as woodframes or forms and Styrofoam or dense insulation foam board. The boxingout method allows for the deck to retain structural integrity during aconcrete pour. This method is discouraged due to the resulting seamscreated from multiple concrete pours called cold joints. Cold joints areof inferior quality when a water tight finished floor is necessary. Theboxing out method is also time-consuming.

The Sleeve method avoids potentials for cold joints however there areseveral disadvantages. If a sleeve is wrongly placed (knocked over) andconcrete is poured you must resort to core drilling to make thecorrection. This often requires cutting into the existing sleeve. Sincemost sleeves are made with ferrous materials, cutting time is increased.The anchors do not allow for easy physical manipulation. Cutting theanchors along with the decking material after the pour of concrete isalso difficult since the anchors consist of high strength steel. The PVCused in this method easily catches on fire when the decking is finallycut through with a torch. Tin sleeves are easy to cut to meet theprofile of the deck, but the material is thin and can easily be dentedor torn off due to its lack of structural strength. Duct tape,styrofoam, and insulation boards are used to fill in the odd shapedvoids, however some problems arise with the use of these materials.Keeping the foam in place is difficult, the duct tape used to sealaround the base and seams does not adhere well when the weather is cold,and the insulation boards along with the other materials burns and meltseasily. Other weather factors prevent the surfaces from being dry.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readilyunderstood, a more particular description of the invention brieflydescribed above will be rendered by reference to specific embodimentsthat are illustrated in the appended drawings. Understanding that thesedrawings depict only typical embodiments of the invention and are nottherefore to be considered to be limiting of its scope, the inventionwill be described and explained with additional specificity and detailthrough the use of the accompanying drawings.

FIG. 1. Collar placed on top flute of metal deck shown.

FIG. 2. Collar with rods meeting deck profile shown.

FIG. 3. Top & side view of rods with interlocking & sliding featuresshown.

FIG. 4. Collar with hold-down clip. Rod with locking mechanism.

FIG. 5. Collar with rods and sealant along mating surface.

FIG. 6. Fire proofing membrane, alignment tool, temporary cap, and watercollar.

DETAILED DESCRIPTION OF THE INVENTION

Reference throughout this specification to features, advantages, orsimilar language does not imply that all of the features and advantagesthat may be realized with the present invention should be or are in anysingle embodiment of the invention. Rather, language referring to thefeatures and advantages is understood to mean that a specific feature,advantage, or characteristic described in connection with an embodimentis included in at least one embodiment of the present invention. Thus,discussion of the features and advantages, and similar language,throughout this specification may, but do not necessarily, refer to thesame embodiment.

Furthermore, the described features, advantages, and characteristics ofthe invention may be combined in any suitable manner in one or moreembodiments. One skilled in the relevant art will recognize that theinvention may be practiced without one or more of the specific featuresor advantages of a particular embodiment. In other instances, additionalfeatures and advantages may be recognized in certain embodiments thatmay not be present in all embodiments of the invention.

These features and advantages of the present invention will become morefully apparent from the following description and appended claims, ormay be learned by the practice of the invention as set forthhereinafter.

Various embodiments of the present invention are comprised of a collar101 defining the form factor of the apparatus and a plurality ofslidably connected and nested rods 105, 106 creating a continuousbarrier conforming to the form factor of the collar 101. While thecollar 101 defines the form factor of the barrier, the slidable rods105, 106 can be adjusted in their relative positions along the formfactor to provide for a barrier that conforms to the contours of thedecking 110 or obstructions. Further embodiments include means to attachthe apparatus to the decking and caps to seal the apparatus duringconstruction activities.

In one embodiment the rods 106 are interconnected one to another througha male-female interlocking structure so that the rods can be connectedinto a continuous barrier 105. The rods 106 are able to slide relativeto each other along the interlocking structure. When the device is setinto position, rods may be slid into a barrier structure that conformsto both planar and non-planar surfaces of the decking 110. As such, thebarrier will be able to provide an effective barrier for furtherconstruction processes, e.g. pouring a cement floor while keeping cementfrom flowing into the desired channel or penetration.

In some embodiments the caps 150, 160, rods 106, and collars 101 may bemade of plastic. The plastic would preferably conform to the following.Sleeves could be used in various environments and would preferably besuitable for different temperatures and humidity levels. Plastic shouldnot become brittle or easily deformed. The plastic would preferablyresist chemicals, solvents, and other material it comes in contact with(such as concrete & sealants). Various sizes, representing various formfactors would be available to accommodate the demand for all pipespenetrating through the floor. Some sleeve sizes could be determined bythe outside diameters of available hole saws. The plastic wouldpreferably be easily cut with a diamond wire cutter or similar tool andbe strong enough to stand on and maintain its installed position withrigidity. It would be advantageous in some embodiments that the plasticbe a highly visible color to reduce tripping hazard of persons workingand moving in the locality of the sleeve.

The barrier structure can be anchored to the decking or othersurrounding supporting structures. In one embodiment the barrierstructure can be anchored using hold-down clips 120. Hold-down clips 120should be strong enough to resist movement of the barrier structureduring construction activities or accidental bumping of the barrierstructure after it is placed. In one embodiment the hold-down clips 120are to be made of high strength steel. Clips 120 should to be strongenough to hold the barrier securely in place. Clips 120 should notdeform easily and they should retain their original shape. Sheet metalscrews can be used on metal decks to anchor the clips 120 to the deck110.

A further embodiment includes the use of sealing material 140 to fill inany gaps between the barrier formed by the rods 105 and the surface uponwhich the barrier is resting 110, e.g. construction decking. The sealingmaterial 140 can be in the form of gaskets, weather sealing tape,glues/silicones/puddy/caulk/mastic, or tape or other such items. In oneembodiment the material should preferably adhere to the base material(metal decking, wood, etc.) in humid and hot or cold environments. Inone application example the sealing is used to keep the poured concretefrom entering the void the barrier is intended to create.

The instant barrier structure comprises two major components: a collar101 and a plurality of interconnected rods 105, 106. For constructionapplications, collars 101 would preferably be manufactured inpredetermined heights depending on the final thickness of the concretethat will be poured on the deck. Such collars 101 would preferably beinstalled level with the top flute of the deck 110. In one embodiment,the bottom rim of the outside surface of the collar 101 would have arecess to allow a metal hold-down clip to anchor the collar 101 to thedeck 110. In another embodiment, the segment inside the collar wouldserve as a ratcheting locking mechanism 190, interfacing with theslidable rods 130 and allowing the rods to only move in one direction(e.g. down toward the deck).

The collars 101 may be manufactured via a variety of standard productionprocesses. In one production mode injection molds would facilitate thespeed and accuracy of the collar production.

The geometry and shape of the rods 106 should provide the barrier withthe strength needed to withstand the pressures that will be exerted onit. In one embodiment, the rods 106, along their axis, have a “keystone” shape that keeps the rods 106 interlocked with each other keepingthe barrier they create from collapsing. The rods are keyed to allowthem to slide one with respect to one another. One side has a guide thatwill slide inside the adjacent rod while the other will have aninversely receiving cavity for the guide of an adjacent rod.

One embodiment would have fine teeth 130 along the outside of the rodthat will serve as a one-way lock with the collar 190, 101. These teeth130 would be angled to allow easy insertion but will have an acute anglethat will prevent it from sliding in the opposite (e.g. upward)direction. In a further embodiment, a recessed location 195 would alsobe available at the bottom end of the rods 106 for the use of thehold-down clips 120 for additional anchoring points.

A further embodiment of the barrier includes caps or covers 150, 170,160 useful e.g. during the construction process. The caps 150, 160 maybe made from a variety of materials, e.g. plastic. Various types of caps(or covers) would be available to facilitate effective and safeconstruction techniques. In one embodiment, a blind cap 150 with asmooth top would be used for the pouring process and when the hole isnot in use. The cap 150 would preferably have a dean flat surface on topto keep it from interfering with the leveling of the concrete. In afurther embodiment the cap 150 may include a handle that wouldfacilitate the removal of the cap 150. The cap 150 may be reinforced asneeded to withstand significant weight placed on top (especially onbarriers with a large surface area).

In a further embodiment an alignment cap 170 (adapted to the top of thecollar) would aid in the centering of the sleeve and could consist ofspoke like wheels 170 converging on a center guide. A shaft 180 would beinserted into this guide at the center of the spokes 170 and slid up anddown to pin point the proper location on the deck.

In a further embodiment, a cap 160 with a long plastic skirt (that willmatch the contour of the inside of the sleeve and can be glued to thesleeve) can be installed at the time the pipe is inserted. It would havea rubber, or similar material, diaphragm (with a smaller diameter thanthe pipe) that would serve as a fire proofing membrane. It would fitsnug against the pipe when inserted.

Barriers can be used wherever penetrations through floors in buildingsare needed. Rods 105, 106 will enable installation of the sleeves invarious floor thicknesses. The profile matching characteristics willmake the sleeves suitable to many different metal decking designs. Onfloors poured as a single flat slab the sleeves could still be installedby having the collar 101 slide up evenly on the rods to the desireddepth.

In one embodiment barriers are installed by following these steps:Proper sleeve location is established as accurately as possible. Whendetermining the center of the barrier by measuring off of grid lines,the centering cap 170, 180 can assist in precisely pin pointing theproper placement for installment. Once the center is found, the collar101 can be secured to the deck 110 with the hold-down clips 120. Weathersealing tape 140 can be installed between the collar and the deck atthis time. If other methods of sealing 140 are preferred then they canbe applied after the sleeve rods 105 have been installed. Rods 105, 106can be inserted after the collar 101 is secured to the decking 110. Rods106 would slide down the inside of the collar 101 until properly seatedagainst the deck 110. Each individual rod should be checked to eliminateany gaps between the deck and the sleeve. Where possible the rods 105,106 should be secured to the deck 110. This could be accomplished withhold-down clips 120 as were used on the collar 101 to aid in stabilityof the sleeve. Remaining rod material left above the desired level canbe sheared off with a diamond impregnated wire blade, hand saw, plastictubing cutters, hack saw, portable band saw, saws all, etc. Cap 150 isto be installed to reinforce the sleeve in case it gets bumped orstepped on or otherwise disturbed during the concrete pouring process tokeep concrete out. Cap 150 should be kept on after the decking has beencut to keep debris from falling through, eliminate a tripping hazard,and from equipment tipping over. The use of a fire proofing sleeve 160is optional and would preferably be installed in unison with the pipeand water collar.

A further embodiment includes an extension 165 to the sleeve that iswithin the concrete. It can be made of variable heights and diameters.For safety reasons it would serve as a water barrier in mechanical roomsin case of flooding. The water would be contained in that roompreventing flow from seeping thru the sleeve to rooms below. Within thesleeve the same fire proofing membrane would be built in. The extension165 could have a flange at concrete level to aid in securing it to thefloor. A gasket, rubber ring, or sealant could be placed in between theconcrete and the flange to make it water tight. This extension 165 wouldbe strong enough to support the pipe protruding through the floor withthe use of riser damps.

In a further embodiment, if the height of the water level is known,another way to accomplish this would be to have the sleeve 101 initiallymade and installed to final specifications.

The above description discloses the invention including preferredembodiments thereof. The examples and embodiments disclosed herein areto be construed as merely illustrative and not a limitation of the scopeof the present invention in any way. It will be obvious to those havingskill in the art that many changes may be made to the details of theabove-described embodiments without departing from the underlyingprinciples of the invention.

What is claimed is:
 1. An apparatus for constructing feed through holesin building fabrication comprising: a collar; a plurality of rods; saidcollar contains a locking structure; wherein said locking structureinhibits motion of said rods in one direction; said rods slidablyconnected one to another forming a continuous barrier; said rodscontacting said collar wherein said collar provides a guide for theshape of said barrier; and said rods have teeth along the rod thatinterconnect with said locking structure wherein said teeth serve as adirectional one-way lock of the position of said rods with said collar.2. The apparatus of claim 1 further comprising: a hold down clip; saidhold down clip configured to anchor the collar to a construction deck.3. The apparatus of claim 1 wherein: said rods have a principal axis;said rods have a key stone shape along their axis; said rods have agrove shape matching said key stone shape; wherein said key stone shapein one rod interlocks with said matching grove in another rod.